Thermoplastic Composites Market Report Scope & Overview:

The Thermoplastic Composites Market size is valued at USD 29.60 Billion in 2025E and is projected to reach USD 54.03 Billion by 2033, growing at a CAGR of 7.83% during 2026-2033.

The Thermoplastic Composites Market analysis highlights the rise in use of lightweight, recyclable advanced materials in the automotive and aerospace & defense industries are driving the demand for thermoplastic composites. Growing need for efficient and high-performing components fuels market growth.

In 2025, thermoplastic composites reduced vehicle weight by 20–30% versus metals; each EV used 15–25 kg in structural and under-hood parts to extend range

Market Size and Forecast: 

• Market Size in 2025E: USD 29.60 Billion 

• Market Size by 2033: USD 54.03 Billion 

• CAGR: 7.83% from 2026 to 2033 

• Base Year: 2025 

• Forecast Period: 2026–2033 

• Historical Data: 2022–2024 

Thermoplastic Composites Market Trends

• Growing usage of lightweight thermoplastic composites in automobile and aerospace industry to improve the fuel efficiency and cut carbon emissions.

• Increasing adoption of recycled and bio-based thermoplastic composites to meet sustainability objectives and environmental regulations.

• Developments in both automated fiber placement and compression molding achieving faster manufacturing rates with material performance.

• Increasing penetration of thermoplastic composites in electric vehicle battery enclosures and structural components to enhance safety and reduce weight.

• Rising demand across electronics sector as they are durable, heat-resistant and light in weight for the manufacturing of devices.

The U.S. Thermoplastic Composites Market size is valued at USD 5.23 Billion in 2025E and is projected to reach USD 9.94 Billion by 2033, growing at a CAGR of 8.36% during 2026-2033. Thermoplastic Composites Market growth is driven by increase of orders in automotive and aerospace production. Driving models include lightweighting and fuel economy, which favors greater use of advanced composites. Industry giants commit to R&D for high-performing recyclable thermoplastics.

Thermoplastic Composites Market Growth Drivers:

• Rising Demand for Lightweight and Recyclable Materials in Automotive and Aerospace Applications

Demand for lightweight, fuel-efficient, and eco-friendly materials to be utilized in the automotive and aerospace industries has been supporting the market growth of thermoplastic composites. These composites combine high specific stiffness, resistance to corrosion and recyclability, which is in concert with worldwide emission decrees plans. The manufacturers are preferring thermoplastic composites over the thermosets due to quicker processing and reusability, driving the market growth.

Replacing steel with thermoplastic composites reduces vehicle weight by 20–25%, improving fuel economy by 6–8% per 10% weight reduction—key for meeting CAFE and Euro 7 standards

Thermoplastic Composites Market Restraints:

• High Processing Costs and Limited Large-Scale Production Capabilities

Although demand is significant, high production and tooling are barriers to the broad use of thermoplastic composites. The elaborate combination of molding or impregnation processes with fibers require costly machinery and highly skilled manpower. Furthermore, the need to scale up to automotive or aerospace demand requires heavy capital investment, effectively excluding smaller producers. Additionally, the absence of uniform recycling and processing systems causes cost inefficiencies that restrict profitability in developing regions.

Thermoplastic Composites Market Opportunities:

• Technological Advancements and Increasing Use in Electric Vehicles (EVs)

Rapid advancements in automated manufacturing technologies and increasing penetration of electric vehicles bodes well for the thermoplastic composites market. Lightweight, high-strength, thermally resistant composites are likewise well suited for EV battery enclosures, interiors and body parts. 3D print technologies and hybrid composite systems are opening up even more ways to improve performance while allowing greater access to some of the transportation/energy storage sectors.

In 2025, over 60% of new EV platforms used thermoplastic composites (e.g., CF-PP, GF-PA) for battery enclosures due to lightweighting, crash resistance, and thermal stability up to 180°C

Thermoplastic Composites Market Segment Analysis

• By matrix type, Polypropylene (PP) led with 38.24% share in 2025, while Polyetheretherketone (PEEK) was the fastest growing with a CAGR of 6.10%.

• By application, Automotive & Transportation dominated with 39.74% share in 2025, while Aerospace & Defense was the fastest growing with a CAGR of 8.83%.

• By form, Sheets & Plates led with 41.60% share in 2025, while Pellets was the fastest growing with a CAGR of 8.21%.

• By reinforcement type, Glass Fiber held 46.30% share in 2025, while Carbon Fiber was the fastest growing with a CAGR of 9.27%.

By Matrix Type, Polypropylene (PP) Leads Market While Polyetheretherketone (PEEK) Registers Fastest Growth

Polypropylene (PP) is leading matrix type in 2025, due to its cost-effective and processable nature along with high strength properties, mainly in automotive and construction industries. With its ability to work with methods of large-volume manufacturing, adoption is increasing. Polyetheretherketone (PEEK) exhibits the highest growth owing to its excellent thermal stability and chemical resistance in aerospace & medical application. In 2025, demand for PEEK-based thermoplastic composite grew by 22%, pointing to increasing adoption in cutting-edge high-performance engineering applications.

By Application, Automotive & Transportation Dominate While Aerospace & Defense Shows Rapid Growth

Automotive and transportation sector is dominated Thermoplastic composites market; driven by growing electric vehicle manufacturing and favorable dynamics towards low weight sustainable materials globally. Body panels, undercarriage systems and interior components Now have a common place for composites in the automotive industry. While, the aerospace and defense industry demonstrates rapid gains as it enjoys enhanced design flexibility, recyclability. Demand for thermoplastic composites in aerospace components is grow by 28% by 2025, the clearest signal yet that industries demand more stronger, lighter materials.

By Form, Sheets & Plates Lead While Pellets Registers Fastest Growth

Sheets & plates segment holds a significant share in 2025 as they are extensively used for structural, automobile and construction components where rigidity and dimensional integrity is required. Due to their ease of production and reusability, they have the advantage over other formats in various industries. Pellets are the fastest growing form due to automation-friendly molding methods. World thermoplastic composites pellets production grew by 19% in 2025 due to higher demand for these materials for both3D-printing and injection molding.

By Reinforcement Type, Glass Fiber Lead While Carbon Fiber Grow Fastest

Glass fiber still being the most important reinforcement material in 2025 due to its cost-effectiveness, durability and mechanical performance in high volume sectors including automotive and consumer goods. It's still taking the place of a metal in structural concepts. Meanwhile, carbon fiber is becoming increasingly popular due to its amazing strength-to-weight and rigidity properties. The application of carbon fiber thermoplastic composites has been rapidly increased in 2025, which is mainly used in electric vehicles, aircraft structure and sports equipment etc., with a growth rate as 26%.

Thermoplastic Composites Market Regional Analysis:

Asia-pacific Thermoplastic Composites Market Insights

In 2025 Asia-Pacific dominated the Thermoplastic Composites Market and accounted for 40.35% of revenue share, this leadership is due to the robust automotive & industrial sector across the region to drive the product demand Material demand gets lift from fast urbanization and infrastructure building in China, India, Japan and South Korea. Increasing manufacture of electric vehicles is adding to composite consumption. The area is a world leader in lightweighting innovation. Production capacity utilization across major economies surpassed 85% in 2025.

China Thermoplastic Composites Market Insights

China continues to be the production hub for thermoplastic composites in 2025, backed by strong government efforts in electric mobility and aerospace sectors. Automation and recycling process technology are enabling domestic suppliers of high-performance composites to increase production. Automotive lightweighting policies accelerate adoption. Export volume of thermoplastic composite components grew by 24% in 2025, emphasizing its global supply strength.

North America Thermoplastic Composites Market Insights

North America is expected to witness the fastest growth in the Thermoplastic Composites Market over 2026-2033, with a projected CAGR of 8.48% due to aerospace, defense and automotive development. Sustainable vehicle design in the U.S. and Canada focus on recyclable, high-strength thermoplastic materials. Key partnerships between material suppliers and OEMs facilitate R&D expansion. The region’s composite processing facilities operated at 80% capacity utilization in 2025.

U.S. Thermoplastic Composites Market Insights

The thermoplastic composites in the U.S. have made a great stride‎ forward, ‎followed by advancements in aerospace and EV industry. In 2025, key participation from players includes the strengthening of automation and fiber placement to maximize structural performance. Such demand is increased by defense modernization programs. Adoption in battery casings and aircraft panels rose by 21% in 2025, underscoring its technological edge.

Europe Thermoplastic Composites Market Insights

In 2025, Europe emerged as a promising region in the Thermoplastic Composites Market, due to sustainability laws & strict emission standards. More automotive OEMs and aerospace companies are turning to recyclable composites. Germany, France and the U.K. are front runners in R&D in advanced materials. Recycled thermoplastic composite content exceeded 18% in European production by 2025.

Germany Thermoplastic Composites Market Insights

Germany remains at the forefront of thermoplastic composite development in Europe focusing on high performance automotive and industrial applications. German companies sped the Chinese digital manufacturing integration and fiber optimization method. Domestic composite production volume rose 17% in 2025, strengthening its role as a European material hub.

Latin America (LATAM) and Middle East & Africa (MEA) Thermoplastic Composites Market Insights

The Thermoplastic Composites Market is experiencing moderate growth in the Latin America (LATAM) and Middle East & Africa (MEA) regions, due to the construction and power sectors. Brazil and UAE lead regional race for renewable energy and automotive investments. Infrastructure projects enhance material utilization. Infrastructure projects enhance material utilization. Import reliance remains high, though local manufacturing expanded by 14% in 2025.

Thermoplastic Composites Market Competitive Landscape:

BASF SE specializes in thermoplastic composites solutions, which are lightweight and robust materials suitable for use in automotive and aerospace sectors. The company is heavily investing in continuous fiber reinforced thermoplastics as it aims to enhance both performance and recyclability. Its innovation centers focus on sustainable and circular production techniques. Its strong partnerships with OEMs are consolidating its position in the worldwide thermoplastic composites market

• In April 2025, BASF unveiled extensively recycled thermoplastic polyurethane (TPU) and polyamide products with a reduced product carbon footprint (PCF) at the PU TECH event, enabling up to 52% GHG reduction in a synthetic-leather automotive seat.

Celanese Corporation is a global producer of specialty materials and chemicals used in most major industries and consumer applications. Its specially formulated polymers provide increased strength-to-weight ratio and thermal stability. The company is focused on sustainability through reduced-emission production and material recycling. Strategic relationships with component suppliers expand its market presence in North America and Europe.

• In January 2025, Celanese expanded its strategic partnership with distributor Biesterfeld to include multiple long-fiber reinforced thermoplastic (LFT) product families, enhancing market access across EMEA and strengthening its engineered polymers portfolio.

Hanwha's focuses on High performance thermoplastic composites for automotive, construction and industrial industries. The company's focus is on automation and on cost efficient mass production for long service life of lightweight materials. In 2025, it was reported that Hanwha had improved its carbon-fiber-reinforced composites for hydrogen storage and aerospace applications. Dedicated to energy saving processes it embeds sustainability in manufacturing. Strategic cooperation in the Asia-Pacific region consolidates its position in advanced composite industry chains.

• In 2025, Hanwha Advanced Materials announced its “NET-won” technology combining aramid fibers with thermoplastics to create car bumper beams 50% lighter than metal while improving crashworthiness — a breakthrough for lightweight composite automotive parts.

DuPont offers the industry’s broadest array of high-performance thermoplastic composites for aerospace, automotive and other uses under the trade name Vespel polyimide composites. It is a leader in mechanical strength and thermal and hydrolytic resistance properties of Vizilon and Zytel product families. The company’s focus on sustainability and digital manufacturing also enhances its global supply chain. Receptive in R&D, recyclable composites formulations are the technology breakthroughs.

• In July 2024, DuPont showcased its Kalrez custom perfluoro elastomer parts at SEMICON West, highlighting advanced composite integration and customer-collaborative innovation in electronics manufacturing environments.

Thermoplastic Composites Market Key Players:

Some of the Thermoplastic Composites Market Companies are:

• BASF SE

• Celanese Corporation

• DSM

• DuPont

• Hanwha

• Lanxess

• Mitsubishi Chemical Advanced Materials

• PPG Industries

• SABIC

• Solvay SA

• Toray Industries Inc.

• Victrex plc

• Teijin Limited

• SGL Carbon

• RTP Company

• Avient Corporation

• Covestro AG

• PlastiComp Inc.

• Asahi Kasei Corporation

• Ensinger GmbH